CN104364620B - 流量传感器及其制造方法 - Google Patents

流量传感器及其制造方法 Download PDF

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Publication number
CN104364620B
CN104364620B CN201280073889.5A CN201280073889A CN104364620B CN 104364620 B CN104364620 B CN 104364620B CN 201280073889 A CN201280073889 A CN 201280073889A CN 104364620 B CN104364620 B CN 104364620B
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mentioned
melt
coating part
shell
cover
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CN104364620A (zh
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荒井聪
角田重晴
半泽惠二
田代忍
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Hitachi Astemo Ltd
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Hitachi Automotive Systems Ltd
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
    • G01F15/00—Details of, or accessories for, apparatus of groups G01F1/00 - G01F13/00 insofar as such details or appliances are not adapted to particular types of such apparatus
    • G01F15/14—Casings, e.g. of special material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1696—Laser beams making use of masks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
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    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
    • B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
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    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being non-straight, e.g. forming non-closed contours
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明提供一种实现流量传感器的生产性提高、高品质化、高可靠化、低成本化的罩与外壳的激光熔敷结构、方法。流量传感器具备外壳与树脂制罩，该外壳收纳具有取入被计测流体的开口部的副通道、配置于上述副通道内且计测被计测流体的流量的传感器元件、以及在电路室内与上述副通道隔离且驱动、检测上述传感器元件的电子部件，该树脂制罩与上述外壳接合，并将上述电路室封闭为与外部大气密封的状态，上述外壳与上述罩的接合部构成为，以包围上述电路室周围的方式形成的第一被熔敷部、以及另一配置为接合的加固用的第二被熔敷部的两被熔敷部通过在上述外壳的接合面及上述罩的接合面上的各个分别对置的位置设置第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，对上述外壳与上述罩进行定位，利用激光照射，上述第一被熔敷部彼此、上述第二被熔敷部彼此进行熔敷。

Description

流量传感器及其制造方法
技术领域
本发明涉及流量传感器及其制造方法。另外，涉及使用激光熔敷的塑料彼此的接合结构及其方法。
背景技术
作为本技术领域的背景技术，具有日本特开2005-246692号公报(专利文献1)。该公报记载了在进行激光熔敷时，在接合部进行两次以上熔敷线上的激光的扫描。另外，该熔敷线上可以在不同的圆周上扫描。
在日本特开2005-246913号公报(专利文献2)中记载了通过使两条激光在使树脂彼此隔着规定的间隔的两条熔敷线上分别进行扫描进行预备熔敷，接下来通过对其中间进行熔敷，进行正式熔敷。
在日本特开2006-73296号公报(专利文献3)记载了具备分别沿整周对外壳与透镜进行激光熔敷的第一熔敷部、在第一熔敷部的外周侧沿整周进行激光熔敷的第二熔敷部的结构或激光熔敷方法。
在日本特开2010-162587号公报(专利文献4)中记载了在电子设备或流量计中，使用包括激光的热熔敷法固定其他部件时，为了抑制热量对电路基板等的影响，在流道保持体上设有绝热部。
在日本特开2010-201695号公报(专利文献5)记载了在使树脂彼此重合的状态下，预备地形成熔敷部后，再次向该熔敷部附近照射激光并使树脂材料彼此互相密合，从而进行正式熔敷的激光熔敷方法。
现有技术文献
专利文献
专利文献1：日本特开2005-246692号公报
专利文献2：日本特开2005-246913号公报
专利文献3：日本特开2006-73296号公报
专利文献4：日本特开2010-162587号公报
专利文献5：日本特开2010-201695号公报
发明内容
发明所要解决的课题
以往，在汽车等的内燃机设有电子控制燃料喷射装置。该电子控制燃料喷射装置具有通过适当地调整流入内燃机的气体(空气)与燃料的量，使内燃机有效地进行工作的作用。因此，在电子控制燃料喷射装置中，需要正确地把握流入内燃机的气体(空气)的流量。因此，在电子控制燃料喷射装置设有测定气体(空气)的流量的流量传感器(气流传感器)。这种流量传感器具备流量检测部或温度检测部，这些配置在外壳(机箱)上。另外，在外壳内的电路室内安装各种电子部件，为了防止配线部等短路或腐蚀等，需要与外部隔离的气密性。因此，以往以确保气密性为目的，采用使用多个粘接剂对外壳与罩进行封闭及固定的方法。作为粘接剂，具有多个固化形式，但鉴于用于汽车等的可靠性，主要使用热固化型粘接剂。但是，在使用热固化型粘接剂的情况下，加热固化需要十分钟以上的时间，因此，存在生产性差之类较大的课题。另外，由于封闭使用大量的粘接剂，因此还存在成本升高的问题。另外，由于粘接剂的溢出控制等，需要不必要的面积，约束设计的自由度。并且，还存在难以控制填充对封闭电子部件适当的粘接剂的量的课题。作为解决这些课题的方法，列举能够不对电子部件带来损害地使罩与外壳精密地直接接合的激光熔敷方法。
在上述专利文献1所公开的技术中，由于对进行接合的部分进行两次以上激光扫描，因此在生产性方面存在较大问题。另外，由于进行两次照射，因此熔敷宽度增大，还发现容易产生溢出。在专利文献2所记载的技术中，由于分别使两个激光进行扫描，因此与专利文献1相同，在生产性方面存在较大的课题。并且，照射两个激光的单元自身高，装置成本也非常高。即使专利文献3所公开的技术，也与上述专利文献1相同，在生产性方面具有问题。在专利文献4所公开的技术中，记载了在流道保持体设有绝热部，但在使用激光熔敷的情况下，热熔融区域仅是激光照射范围附近，不会对电子部件产生影响，没有问题。在专利文献5所记载的技术中，在进行预备熔敷后对其附近进行正式熔敷，但在加压时形成预备熔敷部的树脂彼此的间隙小的情况下等，存在形成预备熔敷部的一方品质或可靠性下降之类的问题。这种问题对专利文献1的其他形式、专利文献2、专利文献3也相同。
因此，本发明的目的在于提供实现流量传感器的生产性提高、高品质化、高可靠化、低成本化的罩与外壳的激光熔敷结构、方法。
用于解决课题的方法
为了解决上述课题，在本发明中，流量传感器具备外壳与树脂制罩，该外壳收纳具有取入被计测流体的开口部的副通道、配置于上述副通道内且计测被计测流体的流量的传感器元件、以及在电路室内与上述副通道隔离且驱动、检测上述传感器元件的电子部件，该树脂制罩与上述外壳接合，并将上述电路室封闭为与外部大气密封的状态，上述外壳与上述罩的接合部构成为，以包围上述电路室周围的方式形成的第一被熔敷部、以及另一配置为接合的加固用的第二被熔敷部的两被熔敷部通过在上述外壳的接合面及上述罩的接合面上的各个分别对置的位置设置第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，对上述外壳与上述罩进行定位，利用激光照射，上述第一被熔敷部彼此、上述第二被熔敷部彼此进行熔敷。
另外，为了解决上述课题，在本发明中，在上述流量传感器中，上述第一被熔敷部彼此进行熔敷而形成的第一熔敷部以包围上述电路室一周的方式形成，上述第二被熔敷部彼此进行熔敷而形成的第二熔敷部以夹着上述电路室的方式至少形成两处以上。
另外，为了解决上述课题，在本发明中，在上述罩或上述外壳设有用于形成上述第一或上述第二被熔敷部、或上述第一及上述第二被熔敷部的突起。
另外，为了解决上述课题，在本发明中，在上述罩或上述外壳的被熔敷部形成凹部，上述罩与上述外壳在至少一部分的被熔敷部彼此嵌合的状态下照射激光，形成接合部。
另外，为了解决上述课题，在本发明中，在流量传感器的制造方法中，在收纳具有取入被计测流体的开口部的副通道、配置于上述副通道内并计测被计测流体的流量的传感器元件、在电路室内与上述副通道内隔离并驱动、检测上述传感器元件的电子部件的外壳以及树脂制罩的两接合面上，以包围上述电路室周围的方式形成的第一被熔敷部及另一配合为接合的加固用的第二被熔敷部的两被熔敷部通过在分别对置的位置，设置在位置重合时第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，使收纳各部件的上述外壳与上述罩重合并加压，从上述罩上进行激光照射，对上述第二被熔敷部间进行熔敷后，对上述第一被熔敷部间进行熔敷而接合上述罩。
发明效果
通过采用本发明，能提供能够抑制由需要电路室周围的封闭的熔敷部的剥离引起的漏电产生，品质及可靠性优异的流量传感器。另外，也能不需要维修或更换所需的透明的加压材料，极大有助于低成本化。
附图说明
图1是表示本实施例的流量传感器的电路室周围的外壳与罩的熔敷形状及制造工序的例子。
图2是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图3是除了流量传感器的电路室周围的外壳与罩的熔敷，还表示并用粘接时的形状的其他实施例。
图4是图3所示的流量传感器的其他实施例。
图5是表示本实施例的流量传感器的电路室周围的外壳与罩的熔敷形状及制造工序的其他实施例。
图6是表示本实施例的流量传感器的电路室周围的外壳与罩的熔敷形状及制造工序的其他实施例。
图7是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图8是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图9是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图10是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图11是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图12是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图13是表示流量传感器的电路室周围的外壳与罩的熔敷形状的其他实施例。
图14是表示将流量传感器安装于汽车等的内燃机的吸气管的例子的图。
图15是表示应用了激光熔敷时的流量传感器的电路室周围的结构的实施例。
图16是表示应用了激光熔敷时的流量传感器的电路室周围的结构的其他实施例。
图17是应用了激光熔敷时的流量传感器整体的主视图。
图18是应用了激光熔敷时的流量传感器整体的后视图。
具体实施方式
以下说明本发明的实施方式。
图17、18表示本发明的一实施方式的流量传感器的卸下了罩(以虚线表示外形)的内部的主视图、后视图。
图14表示将本实施例的流量传感器50安装于汽车等的内燃机的吸气管的例子。在图14中，以从吸气管道10的壁面突出的方式设置外壳200。在外壳200形成取入在吸气管道10中流动的吸气20的一部分的副通道250。副通道250具有导入或排出吸气20的开口部，副通道250的开口部附近设有通道面积逐渐变小的节流件。另外，副通道250在通道路径具有弯曲部，利用该弯曲部使导入副通道250的吸气20折返，为具有空气流在与吸气20的流动方向相反的方向流动的部位的流道结构。在该部位设置流量传感器元件69。
在流量传感器50的外壳200设有搭载流量传感器元件69的驱动、检测电路的电路箱60，利用金属线搭接金属丝68电连接流量传感器元件65与电路箱60。同样地，利用金属丝61连接外部端子70与电路箱60。
如图17、18所示，上述电路箱60设置在设于流量传感器50的外壳200内的电路室40，通过将未图示的罩(以虚线表示外形)激光熔敷在外壳200上，保持电路室与外部大气的气密性。本发明的主要特征涉及该激光熔敷方法。
在本实施例中使用的流量传感器的外壳或罩普遍使用耐热性高的结晶性树脂即聚对苯二甲酸丁二醇酯(PBT)、聚苯硫醚(PPS)、尼龙6(PA6)、尼龙66(PA66)、尼龙6T(PA6T)。但是，本发明也能够使用于流量传感器以外的用途，能够应用于热可塑性树脂全部的激光熔敷。作为热可塑性树脂的非结晶性树脂，列举聚苯乙烯(PS)、丙烯腈-苯乙烯共聚物(AS)、丙烯腈-丁二烯-苯乙烯共聚物(ABS)、聚醚酰亚胺(PEI)、聚碳酸酯(PC)、聚芳基酸酯(PAR)、聚甲基丙烯酸甲酯(PMMA)、环烯聚合物(COP)、环烯烃类共聚物(COC)、聚砜(PSF)、聚醚砜(PES)、聚氯乙烯(PVC)、聚偏二氯乙烯(PVDC)。作为结晶性树脂，除了上述表示的以外，列举聚乙烯(PE)、聚丙烯(PP)、聚甲醛(POM)、聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丙二醇酯(PTT)、聚萘二甲酸乙二醇酯(PEN)、聚醚醚酮(PEEK)、液晶聚合物(LCP)、聚四氟乙烯(PTFE)。包括这些合金材料、玻璃纤维等无机物、特殊的添加剂的热可塑性树脂也为对象。一般来说，相对于非结晶性树脂成形性或透明性优异，结晶性树脂在耐热性或耐药品性方面优异。另外，不仅热可塑性树脂，还可以应用于环氧类等热固化树脂。
激光熔敷是在使光透过树脂与光吸收树脂重合的状态下，隔着光透过树脂进行激光照射，在使另一方的光吸收树脂熔融后，熔融到光透过树脂并接合的方法。因此，作为光透过树脂使用的罩材料优选使用使激光透过20％以上的材质及厚度的自然材料。另一方面，作为光吸收树脂使用的外壳材料期望通过含有炭黑而呈黑色。另外，在本发明的流量传感器中，要求外壳侧具有尤其高的尺寸精度或尺寸稳定性。因此，普遍添加20-40％左右的玻璃材料。但是，由于添加玻璃材料，存在激光透过性恶化的倾向。因此，期望外壳材料的热可塑性树脂的玻璃纤维的添加比例≥罩部件纤维的热可塑性树脂的玻璃的添加比例。另外，结晶性的热可塑性树脂成形时的金属模具温度越低，结晶化度越低，透过率越高。因此，期望外壳材料的热可塑性树脂的结晶化度≥罩部件的热可塑性树脂的结晶化度。
就用于激光熔敷的光源而言，包括半导体激光、YAG激光、纤维激光的具有红外区域的波长的激光在成本方面是有效的，但可以根据树脂的吸收，使用具有其他波长的激光。另外，激光光源的强度分布为高斯分布、顶帽、环形等，能根据所附属的透镜为多种强度分布，但使用顶帽、环形能够均匀地熔敷。
另外，在进行激光照射时，可以使激光光源或工作台移动而进行熔敷，也可以使用检流反射镜高速地进行激光照射。
实施例一
图1是表示本实施例的流量传感器及其制造方法的例子，表示流量传感器50的电路室40周围的外壳200与罩100的接合部的截面形状。在本实施例中，与形成用于封闭电路室40的外壳200的凸部201与罩100的第一熔敷部301时的间隙H1相比，在增大形成配置于其外侧的第二熔敷部302时的间隙H2的状态下进行激光熔敷。以下说明其具体的接合方法。
首先，利用玻璃或丙烯树脂等透明的加压材料2对罩100与外壳200进行加压。另外，此时的加压力期望为0.1MPa以上。接着，以与电路室40侧的罩100与外壳200的凸部201的间隙H1相比，增大配置于其外侧的罩100与外壳200的间隙H2的条件(位置重合时，以在两者的间隙上产生规定的差别的方式实施设计、制造)，对相当于H2的部分进行激光照射并熔敷。之后，在同样利用加压材料2对相当于间隙H1的部分进行加压的状态下进行激光照射，并进行激光熔敷。
在此，以下对发现本结构或方法的理由进行说明。通常，由PBT树脂等构成的外壳200通过注射成型来制造，但由于成形时的收缩，在外壳200上产生缩痕或翘曲。尤其在本实施例的流量传感器50中，外壳200为特别复杂的结构，因此，当使用将外壳200的封闭部分与配置于外侧的进行熔敷的部分的高度设定为相同的金属模具制造时，电路室40侧的凸部201比外侧的被熔敷台阶部202的缩痕多。在成形后，配置于外侧的被熔敷台阶部202的高度比电路室40侧的凸部201高。其结果，在位置重合、加压时，在外侧的被熔敷台阶部产生干涉，在形成于外壳200的电路室40侧的凸部201与罩100产生较大的间隙，激光熔敷后的密封状态为非常差的状态。
另外，即使在成形后凸部201与被熔敷台阶部200的高度自身为相同程度，也同时产生翘曲，因此，在加压时，外侧普遍间隙变小。另外，尤其作为罩100或外壳200的材料使用例如PBT树脂的情况下，还具有以释放外壳200的残留应力为目的实施退火的场合，但由于在退火后产生翘曲，因此与上述相同地在进行加压时，外侧的间隙也普遍变小。
在这种背景下，本发明人仔细研究了产生间隙的情况下对熔敷状态与强度的影响。例如，在使PBT树脂的间隙量为0时，使能成为最适熔敷强度的激光功率为A。接着，当使间隙增加，并以该激光功率A进行激光熔敷时，直到某间隙量，激光熔敷强度不会下降，不会产生与树脂中的热分解对应的气泡(空孔)。另外，当间隙量变大时，熔敷强度逐渐下降，气泡(空孔)的残留比例变大。相对于此，使激光功率与A相比增加时，又发现能够减小相对于间隙量的增加，熔敷强度下降的比例。但是，气泡(空孔)的残留比例具有使激光功率增加了的一方增加的倾向。这是因为，激光功率越高，吸收树脂的温度越高，通过热膨胀或热分解，树脂的密合变好。在该情况下，作为简单的模型，只以激光功率进行说明，但即使使进行扫描的速度变慢即增大必要的输入热量，也能取得相同的效果。
当气泡(空孔)残留时，在长期使用时会在局部引起微小的剥离，由于该微小的剥离的连结，导致产生漏电。相对于此，具有即使稍微产生气泡，也不会引起强度自身的大幅下降的特征。
在流量传感器50中，在外壳200的电路室40的内部安装各种电子部件，为了防止配线部等的短路或腐蚀等，需要气密性。但是，即使气密，也以相对于汽油等所含的腐蚀性气体等进行封闭为目的，因此，具有在连接器连接部的外壳200设置换气用孔的情况，可以只在该部分不为完全的气密。在该情况下，只混入外部大气，但没有腐蚀等的影响。
因此，发现在以与电路室40侧的罩100和外壳200的凸部201的间隙H1相比，配置于其外侧的罩100和外壳200的被熔敷台阶部202的间隙H2变大的方式进行设计、制造的状态下，对相当于间隙H2的部分进行激光照射而进行熔敷。在该情况下，第一熔敷部301与第二熔敷部302相比，气泡(空气)的残留比例变小。另外，此时，期望在金属模具上，以H1为0μm、H2为50μm的方式设计外壳200与罩100，但未限定于该数值，只要根据成形后的外壳200的收缩量进行设定即可。在实际的外壳200中，在上述研究的过程中，判断为H1到75μm、H2到150μm为容许范围。
通过这样，第一熔敷部301不会残留气泡(空孔)，能确保气密性。另外，在只有第一熔敷部301的情况下，与长期的外壳200的翘曲或线膨胀系数差对应的应力集中只施加在该部分，但通过形成能够确保强度的第二熔敷部302，能够避免第一熔敷部301的应力集中。另外，在本实施例的结构的情况下，为了抑制在第一熔敷部301的应力集中，优选在第一熔敷部301的尽量外侧设置第二熔敷部302，通过形成第二熔敷部302，有助于整体的熔敷强度提高，因此耐冲击性也优异。
因此，通过采用本实施例的结构，能利用第一熔敷部301实现气密性的确保，利用第二熔敷部302实现强度提高及可靠性提高。另外，在激光熔敷中，接合的熔敷部的极附近区域进行热熔融。因此，第一熔敷部301与第二熔敷部302的距离D1期望为500μm以上。另外，图1对相对于封闭电路室40的间隙H1，从外侧的间隙部分H2进行激光熔敷进行说明，但也可以为从封闭电路室40的间隙H1部进行激光照射，之后对外侧的间隙部分H2进行激光照射的结构。
这一次，表示相对于封闭电路室40的第一熔敷部301，在外侧设置不需要气密性的第二熔敷部302的结构，但在由于设计上的观点等存在制约的情况下，如图2所示，可以在电路室40内部设置间隙大即气泡(空孔)比例多，不需要气密的第二熔敷部302。另外，只要在生产性或设计上容许，也可以不仅在相对于封闭电路室40的第一熔敷部301为外侧或内侧某一方，而设置在双方。该场合可以提高可靠性。
另外，需要气密性的部分为第一熔敷部301，也能以图3所示那样用粘接剂3置换在图1或图2中表示的间隙大即气泡(空孔)比例多，不需要气密的第二熔敷部302。对于所使用的粘接剂3，以热固化的环氧类粘接剂或以湿气固化的硅型粘接剂是有效的。另外，如图4所示，如果形成平缘，使用以紫外线固化的粘接剂，则生产性提高。即使在该场合，使用兼具热固化或湿气固化的类型也是有效的。
另外，罩或外壳普遍使用热可塑性树脂，但以释放成形时的残留应力，提高尺寸稳定性为目的，普遍在玻璃转变温度以上的温度进行热处理(退火)。在本实施例的流量传感器的情况下，罩薄，刚性低，因此，在进行熔敷的状态下，尺寸变化的影响小，但由于外壳厚度厚且刚性高，因此，对流量传感器带来的尺寸变化的影响大。因此，期望在熔敷前对外壳进行退火。但是，当外壳使用例如PBT树脂，进行140℃数小时的退火时，PBT树脂所含的添加剂的析出或在PBT表面露出的C＝O基潜入分子内，形成较弱的接合层(WBL：Weak BoundaryLayer)。在这种情况下，存在激光熔敷或粘接性恶化的问题。因此，本发明人研究罩与外壳的间隙和熔敷强度的关系的结果发现，随着罩与外壳的间隙变大，熔敷强度的下降比例大。因此，期望至少对进行了退火处理的外壳进行等离子处理、电晕处理、UV臭氧处理、激光处理、药液处理等表面处理，除去较弱的接合层。这些表面处理由于增加或产生C＝O基等功能基，因此，伴随表面能量的增大，熔敷强度也提高，因此是非常有效的方法，即使不实施退火的情况下，只要没有成本上的制约，也希望实施。另外，在进行激光熔敷的情况下，外壳的树脂熔融且浸湿之后，使罩树脂熔融并进行熔敷。因此，在外壳的表面能量过大的情况下，存在难以浸湿罩之类的课题。因此，在进行表面处理的情况下，期望事先为达到熔点时的罩的表面能量＞外壳的表面能量。
实施例二
图5是表示本发明的流量传感器的制造方法的其他实施例的剖视图。通常，在激光熔敷的情况下，利用玻璃或丙烯树脂等透明的材质的加压材料对罩100与外壳200进行加压并尽量减小间隙后，透过加压材料2进行激光照射。但是，例如PBT树脂透过率低，因此，比较需要增大激光功率。另外，罩100的厚度普遍为0.5mm-1.5mm，因此，在该情况下，不止熔敷部，也在罩100的加压材料2的表面照射较高的功率密度的激光。因此，当在未与罩100接合的激光照射面具有附着物时，在向罩100进行激光照射时会引起附着物碳化，劣化到加压材料2的情况多。在该情况下，产生加压材料2的更换或洗涤等劳力与时间。
因此，如图5所示，在利用加压材料2对罩100与外壳200的凸部201的间隙H1的部分进行加压的状态下，对间隙比H1大的被熔敷台阶部202(间隙H2)的部分进行激光熔敷，之后，在除去加压材料2后，对间隙H1的部分进行激光熔敷是有效的。通过这样，第二熔敷部302能实现与加压材料2相同的效果。
如之前所示，由于第一熔敷部301的封闭部分需要气密性，因此必须尽量减小间隙，但即使稍微具有间隙的情况下，也不会引起强度自身的下降。因此，由于未向加压材料2照射激光，因此也不需要是透明的，也能不引起加压材料2的劣化或损伤。通过以上，为对低成本化或生产性非常有效的结构。
图6是表示本发明的流量传感器及其制造方法的其他实施例的剖视图。在外壳200设置比形成具有封闭功能的第一熔敷部301的凸部201的高度低的高度的另一凸部203，对该部分也进行加压。通过这样，能够均匀地进行形成第二熔融部302的部分的加压。此时，在金属模具上，例如期望设计为H1为0μm、H2为50μm、H3为25μm，但只要根据实际的外壳200的形状成为间隙H2＞H3＞H1即可。
此时，在金属模具上，例如期望设计为H1与H3为0μm、H2为50μm，但在实际的外壳200中，根据鉴于缩痕或翘曲的形状，只要为间隙H2＞H3＞H1即可。但是，该情况下的H3及H1是在间隙最大的部分的值。
实施例三
图7是表示本发明的流量传感器及其制造方法的其他实施例的剖视图。在本实施例的结构的情况下，外侧的第二熔敷部302必须为间隙对接合强度的影响少的强力的结构。当罩100厚时，散乱或吸收的影响变大，因此，透过率下降。另一方面，与吸收或散乱对应，发现在罩100的树脂上产生热膨胀，罩100的厚度越厚，越能减小相对于接合强度的间隙的影响。因此，只要只使罩100的外侧102变厚，则能相对于罩100的间隙量更强力。另外，从透过率的观点来看，如果提高形成于外侧的罩100的较厚的凸部102的结晶化度，则能更加相对于间隙为强力。因此，在罩100的厚度厚的情况下，罩100的刚性自身也提高，因此，为对抑制长期的外壳200的变形有效，可靠性优异的结构。另外，如图8所示，如果在罩100上也形成凸部101，则能够形成宽度方向的精度更优异的第一熔敷部301。
相对于此，在形成具有封闭部的第一熔敷部301时，如图9所示，在与罩100的激光熔敷面相反侧设置凹部，使罩100的厚度薄是有效的。在本结构的情况下，在形成第一熔敷部301时，能够利用透明的加压材料2对激光透过的部分加压，能成为加压材料2不会劣化的方法。并且，在提高生产性方面也是有效的方法。另外，可以在相当于第二熔敷部302的部分，在与罩100的激光熔敷面相反侧也设置凹部。
实施例四
图10是表示本发明的流量传感器及其制造方法的其他实施例的剖视图。相对于图7的结构的较厚的罩100的凸部102，为也在外壳200设置凹部并夹持的状态。通常，当在间隙大的状态下进行激光熔敷时，作为激光吸收侧的外壳200过剩地进行发热、热分解，存在容易产生吸收侧的树脂的溢出之类的课题。因此，通过为这种结构，能将溢出的产生滞留于外壳200的凹部206。另外，也能使用于罩100相对于外壳200的定位。因此，是能够利用溢出产生平缘，对应力缓和或强度提高也有效的结构。
图11是图10的变形例，在外壳200的凹部206设置倾斜。通过使用宽度比形成于罩100的凸部102大的尺寸的激光，能够使激光的强度分布变化，增大由溢出构成的平缘的量。
图12表示在形成气密封闭部的第一熔敷部301的罩100侧也设置凸部101，在外壳200也形成凹部205的其他实施例。通过这样，例如即使为形成作为气密封闭部的第一熔敷部301时的间隙比较大的状态，也能抑制溢出绕到电路室40的内部。另外，与图10及图11相同，也能实现由平缘带来的强度提高。
图13是表示本发明的流量传感器及其制造方法的其他实施例的剖视图。之前表示在外壳200侧设置凹部205、206的结构，但从成形性的观点来看，根据外壳200的形状，普遍外壳200的熔敷部为凸形状或平坦的一方尺寸精度优异。在这种情况下，只要在罩100侧设置防止溢出的凹形状104即可。
实施例五
图15是表示本发明的流量传感器及其制造方法的其他实施例的电路室40部分的俯视图。在电路室40的内部配置具备用于计测在主通道中流动的被计测气体的流量的流量检测部或用于计测在主通道中流动的被计测气体的温度的温度检测部64的检测电路的电路箱60。电路箱60利用环氧树脂等模制，设有连接端子61与端子62。连接端子61利用焊接与外部连接端子70接合。图15是相对于封闭电路室40的第一熔敷部301，在外侧沿至少两处以上线上形成不需要气密性的第二熔敷部302的例子。第一熔敷部301为了进行封闭而对电路室40周围整体进行熔敷，因此，在生产性的观点来看，有时需要以尽可能的高速进行熔敷。因此，为了防止热扩散，优选将第一熔敷部301的宽度W1设定为与激光照射宽度相同程度。另一方面，第二熔敷部302不具有封闭功能，因此，熔敷部可以只在一部分。外侧的第二熔敷部302应力集中大，气泡(空孔)的残存大，因此，期望为尽可能增大激光功率并增大熔敷宽度，使熔敷强度高的状态。因此，优选为第二熔敷部302的宽度W2＞第一熔融部301的宽度W1。
另外，关于第二熔敷部302，如图16所示，可以以点进行熔敷。尤其在以点进行熔敷的情况下，能够以ms等级的激光照射进行熔敷，因此，能非常高速地形成第二熔敷部302。因此，本结构是生产性非常优异的激光熔敷结构。另外，由于以点进行熔敷，因此与以线进行照射的情况相比，还具有能够以低激光功率形成较大的熔敷部的优点。即使在该情况下，也期望第一熔敷部301的宽度比第二熔敷部302的点宽大。在上述图16中，点形状的第二熔敷部302在电路室40内部的外侧形成四处，但必须夹着电路室40的内部在外侧形成至少两处以上。另外，不仅电路室40的外侧，还可以只形成在内侧或内侧与外侧双方。
实施例六
图17是应用了本发明的激光熔敷时的卸下了流量传感器的罩(以虚线表示外形)的整体的主视图。另外，图18是应用了本发明的激光熔敷时的卸下了流量传感器的罩(以虚线表示外形)的整体的后视图。在图17、图18中，在透过罩100的状态下表示第一熔敷部301及第二熔敷部302。外壳200呈计测部从凸缘260向主通道的中心方向延伸的结构，在其前端侧设有用于形成副通道的副通道槽251、253。在该实施例中，在外壳200的表背两面设有副通道槽251、253，图17表示表侧副通道槽253，图18表示背侧副通道槽251。用于形成副通道的入口250的入口槽250与用于形成出口的出口槽252设在外壳200的前端部，因此，能够将从主通道的内壁面离开的气体、换言之将在靠近主通道的中央部分的部分流动的气体作为被计测气体从入口取入。在主通道的内壁面附近流动的气体普遍受到主通道的壁面温度的影响，具有与吸入空气等在主通道中流动的气体的平均温度不同的温度。另外，在主通道的内壁面附近流动的气体普遍比在主通道中流动的气体的平均流速慢的流速。在本实施例的流量传感器50中，难以受到这种影响，因此，为能抑制计测精度下降的结构。在图17及图18中，不仅第一熔敷部301及第二熔敷部302，还相对于通道部设置第三熔敷部303。第三熔敷部303普遍对气密性没有要求，比第一熔敷部301残留稍微多的气泡(空孔)。进行焊接时的罩100与外壳200的间隙量H4期望为H2＞H3＞H4≥H1。另外，在本结构中，电路室40与通道部完全分开，但也可以局部重合。在该情况下，该部分为第一熔敷部301。另外，在本结构的情况下，由于形成为非对称，因此，普遍引起翘曲等变形。因此，期望第二熔敷部302也设在通道侧。并且，本结构具有凸缘260，因此，凸缘260附近的外壳200与罩100的加压部有时未均匀地加压。因此，第二熔敷部302期望尽量设在凸缘260侧。
以上，在实施例的方式中，分别地进行说明，但这些并非互相无关，具有一方为另一方的一部分或全部的变形例的关系。
符号说明
1—激光，2—加压材料，3—粘接剂，10—吸气管道，20—吸气，40—电路室，50—流量传感器，60—电路箱，61—连接端子，62—端子，63—抑制痕迹，64—温度检测部，65—热传递面露出部，66—抑制痕迹，67—计测用流道面，68—接合金属丝，69—流量传感器元件，70—外部端子内端，100—罩，101—罩凸部，102—罩凸部，103—罩凹部，104—罩凹部，105—罩凹部，200—外壳，201-203—外壳凸部，205-206—外壳凹部，250—入口槽，251—背侧副通道槽，252—出口槽，253—表侧副通道槽，260—凸缘，261—抵接部，262—外部连接部，301—第一熔敷部，302—第二熔敷部，303—第三熔敷部。

Claims (27)

1.一种流量传感器，其具备外壳与树脂制罩，该外壳收纳具有取入被计测流体的开口部的副通道、配置于上述副通道内且计测被计测流体的流量的传感器元件、以及在电路室内与上述副通道隔离且驱动、检测上述传感器元件的电子部件，该树脂制罩与上述外壳接合，并将上述电路室封闭为与外部大气密封的状态，该流量传感器的特征在于，
上述外壳与上述罩的接合部构成为，
以包围上述电路室周围的方式形成的第一被熔敷部、以及另一配置为接合的加固用的第二被熔敷部的两被熔敷部通过在上述外壳的接合面及上述罩的接合面上的各个分别对置的位置设置第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，对上述外壳与上述罩进行定位，利用激光照射，上述第一被熔敷部彼此、上述第二被熔敷部彼此进行熔敷。
2.根据权利要求1所述的流量传感器，其特征在于，
上述第一被熔敷部彼此进行熔敷而形成的第一熔敷部以包围上述电路室一周的方式形成，上述第二被熔敷部彼此进行熔敷而形成的第二熔敷部以夹着上述电路室的方式至少形成两处以上。
3.根据权利要求1或2所述的流量传感器，其特征在于，
接合上述第二被熔敷部而形成的第二熔敷部形成于凸缘侧。
4.根据权利要求1或2所述的流量传感器，其特征在于，
在上述罩或上述外壳设有用于形成上述第一被熔敷部或上述第二被熔敷部、或上述第一被熔敷部及上述第二被熔敷部的突起。
5.根据权利要求4所述的流量传感器，其特征在于，
在上述罩或上述外壳的被熔敷部形成凹部，上述罩与上述外壳在至少一部分的被熔敷部彼此嵌合的状态下照射激光，形成接合部。
6.根据权利要求1或2所述的流量传感器，其特征在于，
在上述罩上，在形成上述第一被熔敷部或上述第二被熔敷部的部位形成使激光透过的部分的厚度变薄的凹部。
7.根据权利要求4所述的流量传感器，其特征在于，
在用于形成上述第一被熔敷部或上述第二被熔敷部的突起的附近设有上述罩与上述外壳不接触的突起。
8.根据权利要求1或2所述的流量传感器，其特征在于，
形成上述第二被熔敷部的区域的上述罩的厚度比形成上述第一被熔敷部的区域的上述罩的厚度厚。
9.根据权利要求1或2所述的流量传感器，其特征在于，
使形成上述第二被熔敷部的区域的上述罩的透过率比形成上述第一被熔敷部的区域的上述罩的透过率小。
10.根据权利要求2所述的流量传感器，其特征在于，
上述第二熔敷部形成为线状。
11.根据权利要求2所述的流量传感器，其特征在于，
上述第二熔敷部形成为点状。
12.根据权利要求2所述的流量传感器，其特征在于，
上述第二熔敷部的宽度比上述第一熔敷部的宽度大。
13.根据权利要求1或2所述的流量传感器，其特征在于，
在上述副通道的周围形成第三熔敷部。
14.根据权利要求1或2所述的流量传感器，其特征在于，
与上述罩的热可塑性树脂含有的玻璃纤维的量相比，上述外壳的热可塑性树脂含有的玻璃纤维的量多。
15.根据权利要求1或2所述的流量传感器，其特征在于，
与上述罩的热可塑性树脂的结晶化度相比，上述外壳的热可塑性树脂的结晶化度大。
16.根据权利要求1所述的流量传感器，其特征在于，
形成于上述外壳的接合面及上述罩的接合面上的各个分别对置的位置的第一被熔敷部及第二被熔敷部形成为，在上述外壳与上述罩的位置重合、加压时，上述第一被熔敷部间的间隙为75μm以内，以及上述第二被熔敷部间的间隙为150μm以内。
17.一种流量传感器的制造方法，其特征在于，
在收纳具有取入被计测流体的开口部的副通道、配置于上述副通道内且计测被计测流体的流量的传感器元件、在电路室内与上述副通道隔离并驱动、检测上述传感器元件的电子部件的外壳以及树脂制罩的两接合面上，以包围上述电路室周围的方式形成的第一被熔敷部及另一配置为接合的加固用的第二被熔敷部的两被熔敷部通过在分别对置的位置，设置在位置重合时第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，
使收纳各部件的上述外壳与上述罩位置重合并加压，从上述罩上进行激光照射，对上述第二被熔敷部间进行熔敷后，对上述第一被熔敷部间进行熔敷而接合上述罩。
18.根据权利要求17所述的流量传感器的制造方法，其特征在于，
对以包围上述电路室周围的方式形成的上述第一被熔敷部的激光照射使激光照射宽度与熔敷宽度为相同程度地扫描一周。
19.根据权利要求17或18所述的流量传感器的制造方法，其特征在于，
在上述第二被熔敷部间的激光熔敷工序中，在对熔敷上述第二被熔敷部之间以外的区域进行加压的状态下进行激光熔敷，在除去对上述第一被熔敷部间进行熔敷的加压材料后，实施上述第一被熔敷部间的激光熔敷工序。
20.根据权利要求17所述的流量传感器的制造方法，其特征在于，
在使上述外壳与上述罩位置重合并加压，从上述罩上进行激光照射，并对上述第一被熔敷部间进行熔敷后，对上述第二被熔敷部间进行熔敷而接合上述罩。
21.根据权利要求17或18所述的流量传感器的制造方法，其特征在于，
使未熔敷的外壳的突起部与上述罩的间隙H3形成为与上述第一被熔敷部间的间隙H1相同或比间隙H1大，且比上述第二被熔敷部间的间隙H2小地进行上述第一被熔敷部间及第二被熔敷部间的激光熔敷。
22.根据权利要求17所述的流量传感器的制造方法，其特征在于，
具有在上述第二被熔敷部间的激光熔敷工序后，在上述第一被熔敷部间的激光熔敷工序前后对上述副通道周围进行激光熔敷的第三工序。
23.一种流量传感器的制造方法，该流量传感器具备外壳、罩以及内置电子部件的电子电路室，该流量传感器的制造方法的特征在于，
该外壳收纳具有取入被计测流体的开口部的副通道、配置于上述副通道内且计测被计测流体的流量的传感器元件，上述罩与上述外壳接合，并将上述电子电路室封闭为与外部大气密封的状态，上述外壳与上述罩的接合部构成为，以包围上述电子电路室周围的方式形成的第一被熔敷部、以及另一配置为接合的加固用的第二被熔敷部的两被熔敷部通过在上述外壳的接合面及上述罩的接合面上的各个分别对置的位置设置第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，
包括使激光透过上述罩且对上述罩与上述外壳进行熔敷的激光熔敷工序以及粘接上述罩与外壳的工序。
24.根据权利要求17、18、20、22、23任一项所述的流量传感器的制造方法，其特征在于，
在上述第一被熔敷部间或上述第二被熔敷部间的激光熔敷工序前，至少对上述外壳进行等离子处理、UV臭氧处理、激光处理、药液处理。
25.根据权利要求17、18、20、22、23任一项所述的流量传感器的制造方法，其特征在于，
在使熔点下的上述罩的表面能量为上述外壳的表面能量以上的状态下，进行上述第一被熔敷部间及上述第二被熔敷部间的激光熔敷。
26.一种需要气密性的机箱，其具备在室内收纳电子部件的外壳及与上述外壳接合且将上述室内封闭为与外部大气密封的状态的树脂制罩，该需要气密性的机箱的特征在于，
上述外壳由相对于激光具有吸收性的树脂材料形成，
上述罩由相对于激光具有透过性的树脂材料形成，
上述外壳与上述罩的接合部构成为，
以包围上述外壳的开口部周围的方式形成的第一被熔敷部、以及另一配置为接合的加固用的第二被熔敷部的两被熔敷部通过在上述外壳的接合面及上述罩的接合面上的各个分别对置的位置设置第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，对上述外壳与上述罩进行定位，利用激光照射，上述第一被熔敷部彼此、上述第二被熔敷部彼此进行熔敷。
27.一种需要气密性的机箱的制造方法，其特征在于，
使收纳电子部件的外壳由相对于激光具有吸收性的树脂材料形成，
使与上述外壳接合且将上述外壳内部封闭为与外部大气密封的状态的罩由相对于激光具有透过性的树脂材料形成，
在上述外壳及上述罩的两接合面上，以包围上述外壳的开口部周围的方式形成的第一被熔敷部及另一配置为接合的加固用的第二被熔敷部的两被熔敷部通过在分别对置的位置，设置在位置重合时第二被熔敷部间的间隙比第一被熔敷部间的间隙大的台阶而形成，
使收纳电子部件的上述外壳与上述罩位置重合并加压，从上述罩上进行激光照射，对上述第二被熔敷部间进行熔敷后，对上述第一被熔敷部间进行熔敷而接合上述罩。
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